Installation Manual for the G-Wagen Aux Lighting Harness

Installation Manual for the Aux Lighting Harness

Exclusively for Mercedes-Benz Geländewagen W463 Models from 2000 to 2018

W463 Power & Control Harness (2002 to 2013)

 

 

  1. Power & Control Harness
  2. Dual Contact Relay w/ socket
  3. Fuse Holder
  4. Ring Terminal +12V
  5. Ring Terminal - 12V
  6. Weather-Pack Connector for Driving Light Harness
  7. Control Wires Interior Switch
  8. Switch with wire terminals
  9. Control Wire Headlight w/ T-tap & wire terminal

 

Harness Installation for W463 vehicles from 2002 to 2013

 Earlier vehicles from 1996 might be similar.

Connect Memory Saver and Current Drain Tester (see WIS instructions*)
  • Disconnect battery ground cable (see WIS instructions*)
  • Mount the harness with the relay to the existing threaded stud next to the locker solenoid
 Aux light relay location
  • Remove the square protective plastic cover from the remote +12V battery
  • Route the harness along the firewall and fasten it with wire ties
  • Connect the red power wire, with its ring terminal, under the remote +12V battery post

Battery +12V Post

  • Re-install the protective plastic cover
  • Route the harness behind the brake booster, and connect the three brown wires, with their ring terminal, under the remote -12V battery/ground post on the fender wall

Battery -12V Post

  • Please note the Delphi Weather-Pack connector. This is the provided connection for the Driving Light Harness, locate and fasten them towards the left fender – windshield frame gap.

Weather-Pack Connector for RR Harness

 Go to interior switch installation

Amendment for the install in the Mercedes-Benz Geländewagen W463 from 2014 to 2018

 Under the hood 2016 G63

W463 Power & Control Harness for W463 2014 to 2018

 

Parts List

  

  1. Power & Control Harness
  2. Dual Contact Relay w/ socket
  3. Fuse Holder
  4. Ring Terminal +12V
  5. Ring Terminal - 12V
  6. Weather-Pack Connector for Driving Light Harness
  7. Control Wires Interior Switch
  8. Switch with wire terminals
  9. Control Wire Headlight w/ T-tap & wire terminal

 

Harness Installation for W463 vehicles from 2014 to 2018

  • Remove the protective plastic covers from the remote +12V battery
  • Route the harness from the brake booster location to the aux battery posts
  • Connect the red power wire, with its ring terminal, under the remote +12V battery post
  • Connect the brown wire, with its ring terminal, under the remote -12V battery/ground post next to the coolant container

 Aux Battery Posts 2014

  • Cut the wire tie of the left large rubber bellow/grommet and "fish" the switch control wires into the interior. A solid wire, used as a "fish leader", would be a helpful ..

 Rubber Bellow Grommet

Weather-Pack connector

  • Please note the Delphi Weather-Pack connector. This is the provided connection for the Driving Light Harness, locate and fasten them towards the left fender – windshield frame gap.

 

Interior Control Switch Installation W463 2000 to 2018

 

  • Remove the carpeted lower dash cover at the driver side to receive the control wires
  • To install the control switch, cut a square hole 25mm x 12mm into that lower dash cover - choose a switch location which is not obstructed from behind, and can still be easily reached by the driver.

Interior Aux Light Switch

  • Please note: This switch is just the main on & off switch. The aux driving lights are being controlled - while driving - by the Hi-beam stalk switch at the steering wheel
  • Install the control switch
  • Connect the two brown control wires to it, one to the center tap and the other to either side
  • Re-install the lower dash panel and close-off the large rubber bellow/grommet with a wire tie.
  • Remove the left head light cover and left head light
  • Route the black control wire along the inner fender wall into the head light
  • Install the T-tap splice onto the white wire of the lamp plug (high beam) and connect the black control wire to it

 High Beam connection

  • Re-install the headlight and cover
  • Re-connect the battery ground cable and remove the Memory Saver and Current Drain Tester (see WIS instructions*)

 

Now, you can install the Driving Light Harness and connect it to your new aux lights.

 

Installation Manual Auxiliary Driving Light Roof Rack Harness for Mercedes-Benz G Class from 1979 to date

 Roof Rack Harness G-wagen 1979 to date 

Parts Lists

 

Mercedes-Benz G Class (1979 to date) Roof Rack Harness

 

  1. Roof Rack Harness
  2. Weather-Pack Connector, female, Connection to Power & Control Harness
  3. Roof Rack Harness Tail, with pins
  4. Weather-Pack Connectors, male housing
  5. Weather-Pack Connector, female housing with pins & seals for LED light fixture

  

Roof Rack Harness Installation

Mercedes-Benz G Class Vehicles from 1979 to 2002

 

  • Take that end of the Roof Rack Harness with the already installed female Weather-Pack connector, and tie it temporary to the connector of the Power & Control Harness
  • Push the harness into the gap between the left fender and the left windshield frame

 Fender and Hood gap

  • Route the harness inside the left rain gutter up to the roof and tie it to the forward roof rack mounting
  • The use of adhesive or silicon might be necessary to keep the harness securely placed in the rain gutter

 Rain gutter with adhesive

  • Follow the roof rack structure to the aux driving light locations and fasten the harness with wire ties as
  • Install the included female Weather-Pack connector to the cable of the aux light fixture, please see the correct procedure in the amendment below.
  • Connect the aux driving light fixture to the Roof Rack
  • Stow the excess harness length in the engine compartment if necessary and connect the Roof Rack Harness to the prior installed Power & Control harness

 

Mercedes-Benz G Class Vehicles from 2002 on

 These G Class vehicles have the front facing rain gutters, right and left of the windshield, covered up with by a trim piece.

During a recent install on a G550, we were able to pull away the bottom end of this trim piece, and enlarged the drain opening very carefully. Then, with the help of a thin wire, inserted from the top of the rain gutter, the harness end could be pulled up under the trim piece, without removing it. That was the reason behind, leaving the connector housing off…..

 

Otherwise: In order to install the harness into the rain gutter as in earlier vehicle models, this trim piece needs to be removed and re-installed again.

 

  • Take the end of the Roof Rack Harness with the already installed female Weather-Pack connectors, and tie them temporary to the connectors of the Power & Control Harness
  • Push the harness into the gap between the left fender and the left windshield frame
  • Locate the three pop rivets, inside the driver's door opening, which are holding the rain gutter trim piece in place

 Rain gutter rivet

  • Using a 1/8" drill bit, carefully drill-out those three rivets

 drill out rivets

  • The trim is also held by some mastic adhesive along the windshield frame
  • The top of the trim is aligned & positioned by a 1/4" locator pin into the upper horizontal trim, above the windshield

 

  • Start pulling on the trim from the bottom, lift it off the mastic but pull mostly sideward
  • The upper section of the trim needs to be pulled straight out to the side - due to that
  • With the trim piece removed, it is now very easy to lay the harness into the rain gutter all the way to the first roof rack mounting
  • The use of adhesive or silicon might be necessary to keep the harness securely placed in the rain gutter
  • Follow the roof rack structure to the aux driving light locations and fasten the harness with wire ties as needed
  • Install the included female Weather-Pack connector to the cable of the aux light fixture, please see the correct procedure in the amendment below.
  • Connect the aux driving light fixture to the Roof Rack
  • Adjust the harness and stow the excess length in the engine compartment if necessary

 Enlarged rain gutter opening

  • Before re-installing the trim piece again, the drain hole cut-out at the bottom needs to be enlarged to fit the harness as
  • Clean up the residue from the old mastic and apply a thin coat of silicon where the mastic used to be. Squirt a bit of the silicon into the rivet holes before inserting the new
  • A thin coat of silicon on the very top of that trim piece, even inside the door frame will prevent water from dripping down onto the drivers window...how do we know?
  • Line-up the locator pin, make sure the harness is positioned correctly and push that trim piece sideward into its place

 Rain gutter connection at window

  • Use the 1/8" drill bit to find and line-up the rivet
  • Insert new 1/8" x 1/2" pop rivets and fasten the trim
  • Connect the Roof Rack Harness to the prior installed Power & Control harness

 

Weather-Pack Connector Installation

 

  • Trim the wires ends evenly, push on the seals and crimp on, or solder the pins to the
  • Each connector housing has two chambers, "A" & "B" (stamped on the connectors)
  • Always use the chamber "A" for the ground -12V wires (brown)
  • Always use the chamber "B" for the power +12V wires (red or blue)
  • Insert the brown wire with the attached pin into chamber “A” of the housing
  • Insert the red or blue wire with the attached pin into chamber “B” of the housing
  • fold over the locking shell and snap it into place


For installation questions please contact: gwagenaccessories@gmail.com

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